OWNER’S TECHNICAL MANUAL 7785-A5 High … The major components of the pump models in the 7785 series consist of an air-operated motor and a pump tube. The air motor connects directly

DescriptionThe major components of the pump models in the 7785 series consist of an air-operated motor and a pump tube. The air motor connects directly to the double-acting reciprocating pump tube. These high-pressure grease pumps are designed to deliver a range of greases (up to NLGI # 3) and operate directly from their original drums or bulk containers.* Each pump model is designed with a pump tube length to accommodate different size containers. See Figure 1.

Specifications

NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

High-Pressure Grease Pump7785-A5

OWNER’S TECHNICAL MANUAL

Visit our website at www.alemlube.com.au or www.alemlube.co.nz

Service Guide

Alemite CorporationPO Box 473515, Charlotte, North Carolina 28247-3515

Copyright © 1995 by Alemite Corporation

This document contains confidential information that is the property of Alemite Corporation396688 and is not to be copied, used, or disclosed to others without express written permission. Revision (8-97)

SER 7785-A5

7785-A57785-B5

X

Air Inlet

MaterialOutlet

Material Inlet

Y

AirExhaust

Figure 1 High-Pressure Grease Pump Models 7785-A5 and 7785-B5

DescriptionThe major components of the pump models in the 7785 series

consist of an air-operated motor and a pump tube. The air motor connects directly to the double-acting reciprocating pump tube.

These high-pressure grease pumps are designed to deliver a range of greases (up to NLGI # 3) and operate directly from their original drums or bulk containers.*

Models 7785-A5 and 7785-B5

Each pump model is designed with a pump tube length to accommodate different size containers. See Figure 1.

SpecificationsAir Motor

Pump Tube

* Pump model 7785-A5 is operated in various type systems, Refer to the section entitled Alternate Installation for details.

Piston Diameter / StrokeAir Inlet / Outlet

Max. Air Pressure Material

OutletInches Centimeters psi Bars

4-1/4 / 4 10.8 / 10.2 3/4 " NPTF (f) 200 14 1/2 " NPTF (f)

For information on the air motor, refer to Service Guide SER 323440-4

Ratio

Max. Material Pressure

Delivery/Minute(Approximate)* Displacement/Cycle

psi Bars Pounds Kilograms Inches 3 Centimeters 3

40:1 8,000 552 13 6 2.45 40.15

* For detailed information, refer to Figure 3

Table 1 7785 Model Series Specifications

High-Pressure Grease Pump

PumpModel

ContainerSize

ModelWeight X Y

lbs kg lbs kg Inches Cm Inches Cm

7785-A5 400 180 77 35 33-1/8 84 52-1/4 133

7785-B5 120 72 33 25-5/8 65 44-3/4 114

Service Guide

Alemite CorporationPO Box 473515, Charlotte, North Carolina 28247-3515

Copyright © 1995 by Alemite Corporation

This document contains confidential information that is the property of Alemite Corporation396688 and is not to be copied, used, or disclosed to others without express written permission. Revision (8-97)

SER 7785-A5

7785-A57785-B5

X

Air Inlet

MaterialOutlet

Material Inlet

Y

AirExhaust

Figure 1 High-Pressure Grease Pump Models 7785-A5 and 7785-B5

DescriptionThe major components of the pump models in the 7785 series

consist of an air-operated motor and a pump tube. The air motor connects directly to the double-acting reciprocating pump tube.

These high-pressure grease pumps are designed to deliver a range of greases (up to NLGI # 3) and operate directly from their original drums or bulk containers.*

Models 7785-A5 and 7785-B5

Each pump model is designed with a pump tube length to accommodate different size containers. See Figure 1.

SpecificationsAir Motor

Pump Tube

* Pump model 7785-A5 is operated in various type systems, Refer to the section entitled Alternate Installation for details.

Piston Diameter / StrokeAir Inlet / Outlet

Max. Air Pressure Material

OutletInches Centimeters psi Bars

4-1/4 / 4 10.8 / 10.2 3/4 " NPTF (f) 200 14 1/2 " NPTF (f)

For information on the air motor, refer to Service Guide SER 323440-4

Ratio

Max. Material Pressure

Delivery/Minute(Approximate)* Displacement/Cycle

psi Bars Pounds Kilograms Inches 3 Centimeters 3

40:1 8,000 552 13 6 2.45 40.15

* For detailed information, refer to Figure 3

Table 1 7785 Model Series Specifications

High-Pressure Grease Pump

PumpModel

ContainerSize

ModelWeight X Y

lbs kg lbs kg Inches Cm Inches Cm

7785-A5 400 180 77 35 33-1/8 84 52-1/4 133

7785-B5 120 72 33 25-5/8 65 44-3/4 114

Parts And Drawing Breakdown For The 7785-A5


NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

SER 7785-A5 High-Pressure Grease Pump

Revision (8-97) 2 Alemite Corporation

5

6

7

8

10

11

12

13

14

15

16

17

18

19

20

21

20

22

1

2

3

4

9

Figure 2-A High-Pressure Grease Pump Model 7785 Series - Exploded View

2



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

High-Pressure Grease Pump SER 7785-A5

Alemite Corporation 3 Revision (8-97)

Repair Kits

Part No. Kit Symbol Description Notes

398988-2 Kit, Major Repair Includes items on Figure 2-A and 2-B

393622 Kit, Minor Repair (for Pump Tube Assembly) Includes items on Figure 2-A and 2-B

393040-1 Kit, Minor Repair (for Body and Seal Group)

393530-5 Kit, Seal [includes five (5) of item number 15]


ItemNo. Part No. Description Qty Notes Numeric Order

Part # (Item #)

1 10522 Plug, Square Head Pipe, 1/4 " NPTF (m) 1 10522 (1)

2 327706 Adapter, 1/2 " NPTF (m) 1 171009-13 (13)

3 323419 Washer, 1.29 " OD 1 171009-33 (9)

4 324274 Bushing (Rubber) 1 171009-35 (10)

5 323842 Bolt, Eye, 3/8 " NPTF (m) 1 172190-5 (15)

6 Motor Assembly, Air 1 See SER 323440-4 172190-6 (17)

7 328037 Connector, 3/4 " NPTF (m) 1 323419 (3)

8 328031 Coupler Air, 1/2 " NPTF (f) 1 323440-4 (6)

9 171009-33 O-Ring, 1-13/16" ID x 2 " OD 1 323693 (20)

10 171009-35 O-Ring, 1-15/16" ID x 2-1/8 " OD 1 323786 (11)

11 323786 Body 1 323787 (12)

12 323787 Screw, Cap, Socket Head, 1/2 " - 13 3 323842 (5)

13 O-Ring, 1-3/16" ID x 1-5/16 " OD 1 324274 (4)

14 Spacer 1 327706 (2)

15 Seal, 0.812 " ID x 1.062 " OD 1 328031 (8)

16 Ring, Lantern (Brass) 1 328037 (7)

17 Seal, 0.812 " ID x 1.562 " OD 1 332465 (21)

18 337361 Washer, 1.55 " OD 1 332466 (19)

19 332466 Spacer 1 333256 (22)

20 323693 Gasket (Aluminum) 2 337361 (18)

21 332465 Washer, 1.93 " OD 1 337362 (16)

22 333256 Nut, Jam, 2.00 - 16 UN - 2B 1 337363 (14)Legend:

Part numbers left blank (or in italics) are not available separately

designates a repair kit item

3



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

4



38

32

27

27

26

28

29

30

31

35

33

34

36

37

39

40

41

42

43

44

45

44

46

47

27

48

49

50

23

24

25

2324

27

24

24

Figure 2-B High-Pressure Grease Pump Model 7785 Series - Exploded View



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



ItemNo. Part No. Description Qty Notes Numeric Order

Part # (Item #)23 323439 Coupling 2 18850 (49)24 324648 Clip, Spring 4 50666 (37)

25323438-22 Rod, Pump Tube, 13.25 " Long 1 Model 7785-A5 131402 (27)323438-23 Rod, Pump Tube, 5.75 " Long 1 Model 7785-B5 131398-1 (47)

26333257-1 Tube, Pump, 22.25 " Long 1 Model 7785-A5 171032-9 (39)333257-3 Tube, Pump, 14.75 " Long 1 Model 7785-B5 171700-32 (36)

27 131402 Gasket, 1.68 " OD (Aluminum) 4 172190-8 (45)28 337380 Barrel Assembly 1 172190-7 (30)29 Ring, Wear (Glass-Reinforced Nylon) 1 323438-22 (25)30 Seal, 1.00 " ID x 1.375 " OD 1 323438-23 (25)31 Bearing (Brass) 1 323439 (23)32 Spacer 1 323717 (34)33 332246 Piston 1 323732 (38)34 323717 Stop, Ball 1 323734 (48)35 327705 Spring, 1-1/2 " Long Straight 1 323738 (46)36 Ball, 1/2 " Dia. 1 323741 (43)37 50666 Washer, 0.87 " OD (Aluminum) 1 323742 (42)38 323732 Adapter and Insert Assembly 1 323747-2 (41)39 171032-9 Pin, Roll, 3/32 Dia. x 3/4 " Long 1 324648 (24)40 333342 Rod, Primer 1 327705 (35)41 323747-2 Adapter 1 332246 (33)42 323742 Washer, Guide 1 333085 (50)43 323741 Screw, 1.00 " 1 333257-1 (26)44 Washer, 0.93 " OD (Nylon) 2 333257-3 (26)45 Seal, 0.50 " ID x 0.950 " OD 1 333342 (40)46 323738 Body, Valve 1 337376 (32)47 131398-1 Seat, Valve 1 337377 (31)48 323734 Plate 1 337378 (44)49 18850 Nut, Elastic Stop, 1/4 " - 28 1 337379 (29)50 333085 Body, Primer 1 337380 (28)Legend:

Part numbers left blank (or in italics ) are not available separatelydesignates a repair kit item

Repair Kits

Part No. Kit Symbol Description Notes

398988-2 Kit, Major Repair Includes items on Figure 2-A and 2-B393622 Kit, Minor Repair (for Pump Tube Assembly) Includes items on Figure 2-A and 2-B394077-1 Kit, Minor Repair (for Lower Pump Tube Packing)393530-7 Kit, Seal [includes five (5) of item number 30]


5



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



7000

Legend:

Air Pressure

Delivery

6000

5000

4000

3000

2000

1000

00 4 8 12 16 20 24

25

50

75

100

125

150

175

0

2008000

Material Discharge Pressure

Air Consumption

NLGI 2 Grease at 75 F (24 C)Bars

Mat

eria

l Dis

char

ge P

ress

ure

50

100

150

200

250

300

350

400

450

500

550

psi

500

1000

1500

2000

2500

3000

3500

4000

4500A

ir C

onsu

mpt

ion

lpmcfm

100 psi (6.9 Bars)

Pounds/Minute

10 20 Kilograms/Minute

100 psi (6.9 Bars)

50 psi (3.4 Bars)

30 40 50

5000

5500

50 psi (3.4 Bars)

150 psi (10.3 Bars)

150 psi (10.3 Bars)

Accessories

Preventive MaintenanceRefer to section entitled Overhaul for the procedures necessary to perform maintenance.

Performance CurvesA pump’s ability to deliver material is based on the pressure (psi/Bars) and quantity

(cfm/lpm) of air supplied to the motor and the amount of material discharge [back] pressure to be overcome within the system.

This chart contains curves based on four different air pressures. The curves relate delivery in pounds (kilograms) per minute (X axis) to air consumption in cubic feet (liters) per minute (right Y axis) and to material discharge pressure in psi/Bars (left Y axis).

Model Number Air Hose Material Hose Follower Cover Union Bung Adapter Muffler

7785-A5317811-5 317882-7

338912 323847-4321155 326750-B1 324170

7785-B5 338804 323800-4

Table 2 7785 Model Series Accessories

Daily Weekly Monthly Yearly

Wipe Exterior with Clean Cloth Inspect for Air and/or Material Leakage

Table 3 7785 Model Series Preventive Maintenance Schedule

Figure 3 Delivery versus Discharge Pressure and Air Consumption

6



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



OverhaulNOTE: Refer to Figure 2-A and 2-B forcomponent identification on all overhaulprocedures.

Prior to performing any maintenance procedure, the following safety precautions must be observed. Personal injury may occur.

WARNINGDo not use halogenated hydrocarbon

solvents such as methylene chloride or 1,1,1-trichlorethane in this pump. An explosion canresult when aluminum and/or zinc-plated parts inthe pump come in contact with halogenatedhydrocarbon solvents.

Release all pressure within the system prior toperforming any overhaul procedure.

• Disconnect the air supply line from the pumpmotor.

• Into an appropriate container, operate thecontrol valve to discharge remaining pressurewithin the system.

Never point a control valve at any portion of yourbody or another person. Accidental discharge ofpressure and/or material can result in injury.

Read each step of the instructions carefully. Makesure a proper understanding is achieved beforeproceeding.

RemovalNOTE: These model pumps are used innumerous applications and are mountedaccordingly. The following proceduresconsider the pump assembly to be mountedto a container with a cover.

1. Remove the cover and pump assembly from its container.

2. Remove the four bolts that secure the pump assembly to the cover.

IMPORTANT: Remove the follower from thebottom of the container.

Disassembly 1. Unscrew Adapter (2) from the air motor housing.

2. Remove Washer (3) and rubber Bushing (4).

Separate Pump Tube from Air Motor

3. Clamp the motor housing horizontally in a vise.

4. Loosen Jam Nut (22) that secures the Pump Tube assembly to the Air Motor assembly (6).

CAUTIONSupport the Pump Tube assembly during removal.Damage to components can occur.

5. Unscrew Pump Tube (26) [with attached components] from the Air Motor.

6. Pull on the Pump Tube to expose Coupling (23).

7. Remove upper Spring Clip (24) that secures Pump Tube Rod (25) to Coupling (23).

8. Unscrew the Coupling from the air motor piston rod.• Rotate the entire Pump Tube assembly.

Pump Tube Upper Packing

9. Unscrew Cap screws (12) that secure Body (11) to the Air Motor. • Do not remove the Cap Screws from the Body.

10. Remove the Body from the Air Motor.• Use the Cap Screws as levers.

11. Position the Body on the bench with the larger diameter facing upward.

12. Remove aluminum Gasket (20), Washer (21), and additional Gasket (20) from the Body.

13. Remove Spacer (19), Washer (18), and Seal (17).

14. Remove Lantern Ring (16) with Seal (15), and Spacer (14).• Remove the Seal from the Lantern Ring.

15. Remove O-Ring (13), O-ring (9), and O-Ring (10)from the Body.

Pump Tube

16. Clamp the pump tube assembly at Adapter (41)securely in a soft-jaw vise.

7



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



31. Unscrew Primer Rod from Adapter and Insert assembly.

32. Remove Valve Body (46) [with attached components] and Guide Washer (42) from the upper end of the Primer Rod assembly.

33. Remove Screw (43), nylon Washer (44), Seal (45) and additional Washer (44) from the Valve Body.

34. Unscrew the Adapter and Insert assembly from Piston (33).

35. Remove aluminum Washer (37), Ball (36), Spring (35), and Ball Stop (34) from the Piston.

Clean and InspectNOTE: Use the appropriate repair kit forrep lacement par t s . Make sure a l l thecomponents are included in the kit beforediscarding used parts.

1. Clean all metal parts in a modified petroleum-based solvent. The solvent should be environmentally safe.

2. Inspect all parts for wear and/or damage.• Replace as necessary.

3. Inspect Piston (33) and Primer Rod (40) closely. Use a magnifying glass to detect any score marks.• Replace as necessary.

4. Closely inspect the mating surfaces of all check valve components for any imperfections Ensure a smooth and clean contact is obtained when assembled.

AssemblyN OT E : P r i o r t o a s s e m b l y, c e r t a i ncomponents require lubrication in clean oil.Refer to Table 4 for details.

17. Unscrew and remove Tube (26) from the Adapter.

18. Remove upper and lower Spring Clips (24) that secure Pump Tube Rod (25) to upper and lower Couplings (23).

19. Unscrew the Rod from both Couplings.

IMPORTANT: Should the pump contain theobsolete piston (see Figure 5), and stallproperly, certain parts within the major repairkit are discarded. If the new piston is required,order Barrel (28) and Piston (33) separately.

20. Remove lower Spring Clip (24) that secures Piston (33) to lower Coupling (23).

21. Unscrew the Coupling from the Piston.

22. Remove Barrel (28) from the Piston.

23. Remove both aluminum Gaskets (27).

24. Remove brass Bearing (31), Seal (30), and nylon Wear Ring (29) from the Barrel.

25. Unscrew Primer Body (50) from Adapter (41).

26. Remove the Primer Rod (with attached components) from the bottom of the Adapter.

27. Remove Spacer (32) from top of Adapter.

28. Remove Stop Nut (49) from Primer Rod (40).• Support the Primer Rod through the hole as needed.

29. Remove Plate (48), Gasket (27), Valve Seat (47), and additional Gasket (27) from the Primer Rod assembly.

CAUTIONSupport the Piston and Primer Rod assemblyduring Roll Pin (39) removal. Damage tocomponents can occur.

30. Remove Roll Pin (39) that secures Adapter and Insert assembly (38) to Primer Rod (40).• Use a punch and a small hammer.

Item No. on Figure 2-A Description Item No.

on Figure 2-B Description

9 O-Ring, 1-13/16 " ID x 2 " OD 29 Ring, Wear (Glass-Reinforced Nylon)

10 O-Ring, 1-15/16 " ID x 2-1/8 " OD 30 Seal, 1.00 " ID x 1.375 " OD

13 O-Ring, 1-3/16 " ID x 1-5/16 " OD 45 Seal, 0.50 " ID x 0.950 " OD

15 Seal, 0.812 " ID x 1.062 " OD

17 Seal, 0.812 " ID x 1.562 " OD

Table 4 Lubricated Components

8



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

9



Air MotorPiston Rod 14

9131516171810

19

11

122021

22

20

2523

24

Weep Hole Grease Travel

11

1316

26

Pump Tube Upper Packing

NOTE: Refer to Figure 4 for a section viewof the upper packing components.

1. Install O-Ring (9) and O-Ring (10) onto Body (11).

2. Position the Body with the large diameter upward.

3. Install O-Ring (13) into the Body.

4. Install Spacer (14) into the Body.• Make sure the Spacer centers and seats properly.

5. Install Seal (15) [lip end first] into Lantern Ring (16).

6. Install the Lantern Ring assembly into the Body.• Make sure the assembly centers and seats properly.

7. Install and seat Seal (17) [heel end first] into the Body.

CAUTIONDo not place Washer (18) inside Spacer (19).Damage to components will occur.

8. Install Washer (18) and Spacer (19) into the Body.

9. Lubricate the air motor piston rod with grease.

10. Install the Body assembly (while holding the Spacer in place) onto the piston rod.• Use a small hammer or other suitable tool.

11. Rotate the Body to align the product outlet with the hole in the air motor housing.

NOTE: Refer to Figure 2-A for steps 12 and 13.

12. Install Washer (3) and Bushing (4) onto Adapter (2).

13. Install the Adapter assembly into the Body.• Do not tighten.

14. Install Cap Screws (12) that secure the Body to the air motor.• Tighten each Cap Screw securely.

15. Tighten the Adapter assembly into the Body.

16. Install aluminum Gasket (20), Washer (21), and additional Gasket (20) into the Body.• Make sure the components maintain their position.

Figure 4 Upper Packing - Section View

Refer to Figure 2-A Parts List for Parts Identification



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008

10



23

24

25

26

27

2829

3031273233

3435

36

373839

4140

424344

45

47

46

27

4849

50

24

Early ModelPiston Configuration

(No Packings - Obsolete)

Pump Tube

NOTE: Refer to Figure 5 for cross sectionview of pump tube components.

17. Clamp the flats of Piston (33) into a soft-jaw vise.• Make sure the Piston bore points upward.

18. Install Ball Stop (34) [flange end first] into the Piston.• Make sure the Retainer centers and seats properly.

19. Install Spring (35) into the Piston.

20. Install Ball (36) into the Spring.

21. Install Washer (37) onto Adapter and Insert assembly (38).

22. Screw the Adapter and Insert assembly (with Loctite 222) into the Piston. See Figure 2-B.• Tighten securely.

23. Install Washer (44) into Valve Body (46).

CAUTIONUse care seating Seal (45) into the Valve Body.Damage to the Seal can occur.

24. Install and seat Seal (45) [heel end first] into the Valve Body.

25. Install additional Washer (44) and Screw (43) into the Valve Body.• Do not tighten or seat the Screw.

26. Lubricate the Primer Rod with grease.

27. Install the Valve Body assembly onto the upper end of the Primer Rod.• Use a small hammer or other suitable tool.

28. Tighten the Screw into the Valve Body securely.

29. Install Guide Washer (42) onto the Primer Rod.

30. Screw Primer Rod (40) into the Adapter and Insert assembly until the roll pin holes align.

CAUTIONSupport the Primer Rod and the Adapter and Insertassembly during Roll Pin installation. Damage tocomponents can occur.

31. Install Roll Pin (39).• Use a small hammer.

Figure 5 Pump Tube Assemblies323730-A1 and 323730-B1 - Section View

Refer to Figure 2-BParts List

for Parts Identification



NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



32. Install Valve Seat (47), Plate (48), and Stop Nut (49)onto the Primer Rod.• Tighten the Stop Nut securely. Place a small punch

into the hole of the Primer Rod to prevent its rotation

33. Position Adapter (41) horizontally into the vise.

Internally-Threaded End of Adapter

34. Install Gasket (27) into the internally-threaded end of the Adapter.

35. Install the Primer Rod and Piston assembly (Piston end first) into the Adapter.• Center and seat all components properly. Pull on the

Piston as necessary. Use care to ensure the Gasket does not move.

36. Install the additional Gasket (27) onto Valve Seat (47).

Externally-Threaded End of Adapter

37. Install Spacer (32) into the externally-threaded end of the Adapter.• Make sure the Spacer centers and seats properly.

38. Install Gasket (27) into the Adapter.

39. Position Barrel assembly (28) with the large diameter pointing upward.

40. Install Wear Ring (29) into the Barrel assembly.

41. Install and seat Seal (30) [lip end first] into the Barrel assembly.

42. Install Bearing (31) into the Barrel assembly.

CAUTIONUse care installing the Barrel assembly over thethreads of Piston (33). Damage to the Seal canoccur.

43. Install the Barrel assembly (large diameter first) onto Piston (33).• Make sure the Barrel assembly seats properly against

Spacer (32).

44. Install Gasket (27) onto the Barrel assembly.

45. Screw the upper and lower Couplings (23) onto each end of Pump Tube Rod (25) until the Spring Clip holes align.

46. Install Spring Clips (24).

47. Screw the Rod and Coupling assembly onto the Piston.• Install the Spring Clip.

IMPORTANT: If a primer is used withLoctite 222, the curing time is greatlyreduced.

48. Screw Pump Tube (26) onto Adapter (41)[with Loctite 222]. See Figure 2-B.• Do not tighten.

49. Screw Primer Body (50) [with Loctite 222] into the opposite end of the Adapter. See Figure 2-B.• Do not tighten.

50. Screw Jam Nut (22) onto the Pump Tube.

51. Push on Plate (48) to expose Coupling (23) from the Pump Tube as necessary.

Attach Pump Tube to Air Motor

52. Screw the Coupling onto the air motor piston rod until the Spring Clip holes align.• Rotate the entire pump tube assembly.

53. Install the Spring Clip.

54. Screw the pump tube assembly into Body (11).

55. Place a large wrench or other suitable tool into the slot of Primer Body (50).• Tighten all the components of the assembly securely.

Crush all gaskets.

56. Tighten Jam Nut (22).

OperationBench Test and Prime

NOTE: Perform the following procedures ata pressure not to exceed 40 psi (2.8 Bars).

1. Make sure air pressure at the regulator reads zero.

2. Connect a product hose to the pump’s material outlet.

3. Place the hose into an appropriate collection container.

4. Install air Connector (7) to the inlet of the air motor.

5. Connect Air Coupler (8) to the Connector.

6. Slowly supply air pressure to the pump’s motor.• The pump assembly should cycle.

If the pump assembly does not cycle, refer to the Troubleshooting Chart for details.

11


NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



Priming

With air pressure at zero:

7. Place the pump in the product to be dispensed.

8. Slowly supply air pressure to the pump’s motor.

9. Allow the pump to cycle slowly until the system and product is free of air.

If the pump assembly does not prime, refer to the Troubleshooting Chart for details.

10. Check the motor for air leakage.

If the motor leaks, refer to the Air Motor Service Guide for details.

Stall Test

WARNINGShould leakage occur anywhere within the

system, disconnect air to the motor. Personalinjury can occur.

With air pressure at zero:

11. Attach a control valve to the outlet hose of the pump.

12. Set the air pressure to 100 psi (6.9 Bar).

13. Operate the control valve into a container.

14. Allow the pump to cycle until the system and product is once again free of air.

15. Shut off the control valve.• The pump should not cycle.

If the pump cycles slowly (once or twice a minute) or continuously, refer to the Troubleshooting Chart fordetails.

InstallationNOTE: The following procedures considerthe pump assembly to be installed onto acontainer with a cover.

1. Install the bolts that attach the cover to the pump assembly.• Tighten the bolts securely.

2. Place the follower into the container.

3. Press downward and maneuver the follower until grease appears around its edges and center hole. • Make sure all air is removed.

4. Install the pump assembly through the follower and onto the container.

5. Secure the cover and pump assembly to the container.

Additional items that should be incorporated into the air piping systems are listed in Table 5.

* Although the air motor is lubricated at the factory, the life of the motor can be extended with the use of a lubricator.

Alternate InstallationsPump model 7785-A5 is often mounted:• from either a single- or dual-post hoist• in bulk grease distribution systems

When either of these type arrangements are employed, alternate accessory items must be purchased. See Table 6.

Part Number Description

338862 Moisture Separator/Regulator & Gauge Combination

5608-2 Moisture Separator

7608-B Regulator and Gauge

5908-2 Lubricator *

Table 5 Air Line Components

Application Followers Adapter Kit Primer Body

Single-Post Hoist 327242327247

Dual-Post Hoist 327690

Bulk Grease 333693*

* 1-1/2 " NPTF (m)

Table 6 Accessory Items for Alternate Installations

12


NSWTEL: (02) 9939 0711FAX: (02) 9939 0411

QLD/PNGTEL: (07) 3204 9166FAX: (07) 3204 1224

VIC/TASTEL: (03) 8787 8288FAX: (03) 8787 8266

WATEL: (08) 9209 3066FAX: (08) 9209 3933

SA/NTTEL: (08) 8241 7111FAX: (08) 8241 7011

NZTEL: (09) 447 1007FAX: (09) 447 1008



d

Troubleshooting ChartPump Indications Possible Problems Solution

Pump does not cycle 1. Air motor not operating properly

2. Pump tube jammed and/or contains loose components

3. Insufficient air pressure

1. Inspect air motor and rebuild or replace as necessary

2. Rebuild pump tube

3. Increase air pressure

Pump will not prime 1. Excessive cycling speed2. Pump leaking internally

1. Reduce air pressure2. See Internal Leaks

Pump cycles rapidly 1. Product source empty 1. Replenish product

Pump cycles continuously, or slowly (once or twice/minute)

1. Pump leaking internally 2. Pump leaking externally3. Distribution system leaking

1. See Internal Leaks2. See External Leaks3. Correct leak

External Leaks

Product leakage visible at weep hole in Body (11)

1. Damaged Seal (17)

2. Damaged air motor piston rod.

1. Separate pump tube from air motor and replace Seal (17)

2. Inspect piston rod and replace as necessary

Product leakage visible at bottom of Body (11)

1. Pump tube not sufficiently tight2. Damaged Gasket(s) (20)

1. Tighten pump tube assembly2. Separate pump tube from air motor

and replace Gaskets (20)

Air leakage at weep hole in Body (11)

Damaged Seal (15) Separate pump tube from air motor and replace Seal (15)

Product leakage visible at weep hole in Tube (26) and/or Adapter (41)

1. Pump tube not sufficiently tight2. Damaged Gasket(s) (27)

1. Tighten pump tube assembly2. Disassemble pump tube and replace

Gaskets (27)

Internal Leaks

Pump does not prime or cycles continuously, or slowly (once or twice/minute)

1. Foreign material between Ball (36) and Adapter and Insert assembly (38)

2. Foreign material between Valve Body (46) and Valve Seat (47)

3. Worn or damaged Ball (36)4. Worn or damaged Adapter and Insert

assembly (38)5. Worn or damaged Valve Body (46)6. Worn or damaged Valve Seat (47)7. Worn or damaged Seal (30)8. Worn or damaged Piston (33)9. Worn or damaged Seal (45)

10. Worn or damaged Primer Rod (40)

Locate and eliminate source of foreign material.

Disassemble pump tube, clean, inspect and replace worn or damaged components.

Changes Since Last Printing

Excluded Kit Symbol from Item 35 on Figure 2-B

13

Documents

OWNER’S TECHNICAL MANUAL 7785-A5 High … The major components of the pump models in the 7785 series consist of an air-operated motor and a pump tube. The air motor connects directly